Custom Corrugated Cardboard Inserts

Measuring Products for a Snug Fit

Accurate measurements are the whole job. Measure each product at its widest point, including caps, pumps, handles and any packaging it already sits in. For round items such as bottles, measure the diameter at the shoulder and at the base, because a cut-out sized only to the neck will let the body tilt.

Allow a small clearance, usually 1 to 2 mm, around each cut-out so products slide in without forcing. Too tight and your packers will struggle and tear the board; too loose and the item rattles. If your products vary slightly from batch to batch, tell us the largest size you expect so the insert works for all of them.

If possible, send us a sample of each product. We can then cut a plain test insert, check the fit and adjust it before the main run is printed and produced. This step saves far more time than it costs, especially for kits with several differently shaped items.

An insert only works if it fits the box it goes into. If you already have boxes, send us their internal dimensions, measured inside the walls rather than outside. If you are starting from scratch, we can make the box and insert together so the two are designed as one unit, which is the most reliable route.

Mailer boxes with a tuck-in lid are the most common partner because the lid presses down on the insert and holds everything firm. Shipping cartons with flaps work too, but leave a little headroom above the products so the top flaps do not press on caps or pumps.

Board Grades for Corrugated Inserts

Most inserts are cut from E flute, a thin corrugated board around 1.5 mm thick that folds neatly, holds crisp die-cut edges and takes print well. It suits cosmetics, small electronics, candles and jars. For heavier products such as glass bottles of spirits or bulky hardware, B flute gives more crush strength and a deeper cushion.

Very fine work, such as tiny vials or tightly spaced cells, sometimes needs an even thinner flute so the cut edges stay clean. We will suggest the board on your custom quote based on the weight and fragility of what you send us. Brown kraft liner keeps a utility look, while a white liner looks cleaner and shows printed colour more accurately.

Printing the Inside of the Box

An insert is the first thing a customer sees once the lid is lifted, so it is worth considering print. A single colour logo on the top surface is the simplest upgrade. Full-colour print allows instructions, a short brand message or a numbered layout that tells the customer which item to use first.

Product launch kits sent to press or influencers often use the insert as a reveal: each cut-out is labelled, and the board around the products carries a short line about each one. Subscription boxes use the same idea to explain what is in this month's selection without adding a separate printed card.

If the insert will be hidden under a tray or used purely for protection, leave it plain. You save on print and the board does exactly the same job. Printed tissue, stickers and cards that sit on top of the insert are covered in our box extras for unboxing.

Mistakes That Make Inserts Fail

The most common problem is measuring the product without its cap, pump or outer carton, then finding the real item will not seat. Always measure exactly what will go into the pocket on packing day. The second is forgetting about orientation: a pump bottle laid on its side needs a different cut-out to one standing upright, and the pump may need its own recess so it is not pressed during transit.

Another trap is designing an insert that looks perfect but is slow to pack. If a packer has to bend three flaps and thread a tab before each order, a busy week will expose it quickly. Simple platforms and cradles that drop into the box in one movement are usually the better choice for high volumes, with folded multi-part designs saved for launch kits and gift sets.

Finally, check how the customer will get the products out. A pocket that grips a jar tightly is great in transit but frustrating at home. A small finger notch beside each cut-out solves this and costs nothing extra in the die line. Heavy glass sets that still rattle in E flute usually need the box upgraded to double wall corrugated boxes as well.

Ask for the Plain Test Insert First

An insert is the one item where a plain test cut earns its keep. Send one of each product, or exact measurements taken with caps, pumps and outer cartons in place, and the internal size of the box measured inside the walls. We cut a blank insert, you drop your products in, and any pocket that grips too hard or sits too loose is fixed before a single printed sheet is made.

Tell us how the box opens and which way each item faces, because a pump bottle lying flat needs a different cut-out to one standing up. A custom quote comes back by email within one working day with prices from £0.25 per insert, and the free proof shows the flat dieline with every cut-out, fold and finger notch marked. Production takes 4–7 working days after approval and tracked delivery to UK mainland addresses is free, arriving flat in 2–3 working days. Inserts that arrive damaged or misprinted are reprinted or refunded when reported within 10 days. Very delicate instruments that need more cushioning than board gives can move to foam inserts cut to shape in the same box.